Particle separation system and method

ABSTRACT

A particle separation system may comprise a vessel having at least one side wall and a bottom wall forming an internal chamber within the vessel, a filtration unit positioned within the vessel and including a first filtration pack including a first plurality of filter elements, an inlet for moving pre-separated fluid into the vessel, and an outlet in fluid communication with the filtration pack for moving processed fluid out of the vessel, a rate of pre-separated fluid flow into the vessel and a rate of processed fluid flow out of the vessel each being between about 10 and about 1000 gallons per minute (GPM) and a flux within the filtration unit is less than or equal to about 0.05 gallons per minute per square foot (GPM/ft 2 ).

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Application Ser. No.62/419,296, filed Nov. 8, 2016, and entitled “Particle Separation Systemand Method,” which is hereby incorporated by reference herein in itsentirety.

BACKGROUND

Petroleum producers, refiners, construction de-watering systems, gasprocessors (including onshore and offshore), and chemical manufacturersutilize separation systems to filter, process, and recover chemicalproducts, such as particulates, hydrocarbons, etc., from a variety ofraw material process streams. Separation systems of this naturegenerally have an inlet stream that can comprise a complex heterogeneousmixture of solids, liquids, and gaseous materials that requireprocessing to achieve separation of one or more components with apredetermined efficiency. Developers of separation systems are alwayslooking for ways to increase the efficiency and output and decrease theoverall operating costs of such systems.

SUMMARY

Some embodiments provide a particle separation system may comprise avessel having at least one side wall and a bottom wall forming aninternal chamber within the vessel, a filtration unit positioned withinthe vessel and including a first filtration pack including a firstplurality of filter elements, an inlet for moving pre-separated fluidinto the vessel, and an outlet in fluid communication with thefiltration pack for moving processed fluid out of the vessel, a rate ofpre-separated fluid flow into the vessel and a rate of processed fluidflow out of the vessel each being between about 10 and about 1000gallons per minute (GPM) and a flux within the filtration unit is lessthan or equal to about 0.05 gallons per minute per square foot(GPM/ft²).

Other embodiments provide, a particle separation system comprising, avessel having at least one side wall and a bottom wall forming aninternal chamber within the vessel, a filtration unit positioned withinthe vessel and comprising a first filtration pack comprising a firstplurality of filter elements having a first plurality of outlets, afirst hollow manifold having a first plurality of inlets, a number ofthe first plurality of inlets being equal to a number of the firstplurality of outlets, the first plurality of outlets and the firstplurality of inlets being capable of coupling such that a flow througheach of the first plurality of filter elements enters the firstmanifold, the first hollow manifold including a first outlet channel forflow from the first manifold to a processed fluid conduit, a secondfiltration pack comprising a second plurality of filter elements havinga second plurality of outlets, a second hollow manifold having a secondplurality of inlets, a number of the second plurality of inlets beingequal to a number of the second plurality of outlets, the secondplurality of outlets and the second plurality of inlets being capable ofcoupling such that a flow through each of the second plurality of filterelements enters the second manifold, the second hollow manifoldincluding a second outlet channel for flow from the second manifold tothe processed fluid conduit.

Still other embodiments provide a method of separating particles fromfluid, the method comprising the steps of moving pre-separated fluidthrough an inlet into a vessel at atmospheric pressure, the vesselhaving at least one side wall and a bottom wall forming an internalchamber within the vessel, wherein the pre-separated fluid is moved intothe vessel at a rate of between about 10 and about 1000 gallons perminute (GPM), moving the pre-separated fluid into and through afiltration unit utilizing a downstream pump, the filtration unitincluding a plurality of filtration packs each having a plurality offilter elements, thereby creating a flux in the filtration pack of lessthan or equal to about 0.05 gallons per minute per square foot(GPM/ft²), and moving fluid processed by the filtration unit to anoutlet and out of the vessel.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram depicting an exemplary particle separation systemaccording to some aspects of the present disclosure;

FIG. 2 is a top perspective view depicting a separation vessel and apump system of the particle separation system depicted in FIG. 1;

FIG. 3 is a top perspective view of the separation vessel of FIG. 2 witha top wall removed and depicting a front and side wall as transparent todepict internal elements of the separation vessel including a weir, afiltration unit including one or more filtration packs, and outletmanifolds in fluid communication with the filtration packs;

FIG. 4 is a top perspective view of a filtration pack positioned withinthe separation vessel of FIGS. 2 and 3 for separating fluids and solids;

FIG. 5 is a cross-sectional view of a single filter element of thefiltration pack depicted in FIG. 4, and depicting a flow of fluidthrough the filter element;

FIG. 6 is a diagram depicting various possible sensors and instrumentsthat can be utilized within the separation system of FIG. 1;

FIG. 7 is a partial, top perspective view of a separation vessel with atop wall removed and depicting a filtration unit including a pluralityof filtration packs each including a plurality of filter elements;

FIG. 8 is a front, top perspective view of a filtration pack of FIG. 7;

FIG. 9 is a bottom perspective view of a connection between the filterelements of the filtration pack of FIG. 8 and a manifold;

FIG. 10 is a bottom perspective view of the filtration pack of FIG. 8;

FIG. 11 is a top perspective view of an embodiment of a two stagefiltration system including any of the methods of particle separationand/or any of the separation vessels disclosed herein;

FIG. 12 is a diagrammatic view of a portion of the two stage filtrationsystem of FIG. 11;

FIGS. 13A-13C depict different exemplary configurations for any of theseparation vessels disclosed herein; and

FIGS. 14A-14C depict alternative nesting configurations for filterelements disposed within any filtration pack disclosed herein.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. Unless specified or limited otherwise, theterms “mounted,” “connected,” “supported,” and “coupled” and variationsthereof are used broadly and encompass both direct and indirectmountings, connections, supports, and couplings. Further, “connected”and “coupled” are not restricted to physical or mechanical connectionsor couplings.

The following discussion is presented to enable a person skilled in theart to make and use embodiments of the invention. Various modificationsto the illustrated embodiments will be readily apparent to those skilledin the art, and the generic principles herein can be applied to otherembodiments and applications without departing from embodiments of theinvention. Thus, embodiments of the invention are not intended to belimited to embodiments shown, but are to be accorded the widest scopeconsistent with the principles and features disclosed herein. Thefollowing detailed description is to be read with reference to thefigures, in which like elements in different figures have like referencenumerals. The figures, which are not necessarily to scale, depictselected embodiments and are not intended to limit the scope ofembodiments of the invention. Skilled artisans will recognize theexamples provided herein have many useful alternatives and fall withinthe scope of embodiments of the invention.

Referring now to FIG. 1, an exemplary particle separation system 20 isdepicted. The particle separation system generally includes a sourcetank(s) 22 holding pre-separated fluid to be processed by the particleseparation system 20, a pump system 24 that is configured to move fluidthrough the particle separation system 20, and a separation vessel 26for separating solids from fluids. While a source tank 22 is depicted, apressurized flow (e.g., at a varying flow rate) of pre-separated fluidcan be received from some other process or any other suitable source.

Pre-separated fluid is transferred into the source tank(s) 22, forexample, by trucks 28. In the depicted embodiment, the trucks 28 arefilled with pre-separated fluid at a remote location and transported tothe location of the particle separation system 20. The pre-separatedfluid can be transferred from the trucks 28 to the source tank(s) 22 inany suitable manner. In other illustrative embodiments, thepre-separated fluid can be transferred to the source tank(s) 22 is othermanners, for example, through a pressurized flow from another location.Alternatively, the pre-separated fluid can be transferred by anysuitable vehicle, vessel, or fluid transfer system. Still further, whilethe fluid in the source tank(s) 22 is referred to herein as beingpre-separated fluid, the fluid can be any pre-separated fluid capable ofseparation into solids and fluids. More particularly, pre-separatedfluid refers to any fluid, for example, water, an amine, or any otherfluid, that is contaminated by dirt or other debris, hydrocarbons,chemicals, and/or any other contaminants regardless of the form (e.g.,solid, liquid, etc.). In some embodiments, the pre-separated fluid isproduced water, which is a by-product of hydrocarbon extraction methodsand consists of water mixed with oil and particulate of variousconcentrations. In some embodiments, the pre-separated fluid is wastewater, for example, from a refinery, chemical plant, gas plant, or othersimilar location. In still other embodiments, the pre-separated fluid isindustrial waste water, run-off, or construction de-watering. Producedand waste water are both by-products of chemical processes that must betreated before reuse or disposal.

Referring to FIGS. 1 and 2, the flow of fluid in the particle separationsystem 20 is also depicted. Arrow 30 depicts the transfer ofpre-separated fluid from, for example, the trucks 28 to the sourcetank(s) 22. Pre-separated fluid in the source tank(s) 22 is pumpedthrough a first transfer or inlet line 40 (arrow 42) to the pump system24 and through a second transfer or outlet line 44 (arrow 46) to theseparation vessel 26. After the pre-separated fluid is filtered in theseparation vessel 26, processed fluid (i.e., pre-separated fluid thathas been processed by the separation vessel 26, for example, water,amine, or any other suitable fluid) is pumped through a third transferor inlet line 47 (arrow 48) to the pump system 24 and through a fourthtransfer or outlet line 50 (arrow 52) back to the source tank(s) 22.While the source tank 22 for produced and processed fluid is shown asbeing the same, different tanks or different compartments within thesame tank can be utilized.

While a single source tank 22, a single pump system 24, and a singleseparation vessel 26 are depicted in FIG. 1, the particle separationsystem 20 can include any suitable number of source tanks 22, pumpsystems 24, and/or separation vessels 26.

The pump system 24 and the separation vessel 26 are shown in more detailin FIG. 2. The pump system 24 is depicted as having a pump outlet 80 influid communication with a separation vessel inlet 82 by way of thesecond transfer or outlet line 44 to move pre-separated fluid into theseparation vessel 26. The pump system 24 includes an inlet pump 84 thatpumps pre-separated fluid from the source tank(s) 22, through the secondtransfer line 44 into the separation vessel 26. The pump system is alsodepicted as having a plurality of pump inlets 86 connected to a manifold88, wherein each of the pump inlets is in fluid communication with arespective separation vessel outlet 90 by way of the third transfer orinlet lines 46. Processed fluid is moved through each of the thirdtransfer lines 46 into the manifold 88 and through the fourth transferline 50 to the source tank(s) 22 by an outlet pump 92. The manifold 88streamlines each of the third transfer lines 46 into a single fluidstream to the source tank(s) 22.

The separation vessel 26 generally includes a top wall or covering 100(optional), a bottom wall 102, and one or more side walls 104 forming aninternal or main filtration chamber 105 within the separation vessel 26,as seen in FIGS. 2 and 3. One or more portions of the separation vessel26 can be made of fiberglass or another suitable material that canprevent corrosion when pre-separated fluid containing harmful chemicalsis processed by the separation vessel 26. In illustrative embodiments,the separation vessel 26 is not pressurized (i.e., is at atmosphericpressure). In other illustrative embodiments, the separation vessel 26can be pressurized. The separation vessel 26 can include a weir 108spaced from the separation vessel inlet 82. The separation vessel inlet82 can be positioned adjacent a bottom of the weir 108 such thatpre-separated fluid must travel upwardly and over the weir 108. The weir108 extends from the bottom wall 102 of the separation vessel 26 andends short of a fluid height 110 in the separation vessel 26. The weir108 functions to provide “bulk knock out” of very large particles orbulk oil/immiscible liquid content (that will sink to the bottom of theweir 108 and not enter the main filtration chamber 105) and serve as astrong physical barrier to the filtration technology (e.g., filtrationunit, filtration pack, filter elements, etc.) in the event a strongpressurized stream enters the separation vessel 26. In some embodiments,the weir 108 is not utilized.

As seen in FIGS. 3 and 4, a filtration unit 120 is positioned within theinternal chamber 105 of the separation vessel 26 after the weir 108 (ina flow path between the separation vessel inlet 82 and the separationvessel outlet 90). The filtration unit 120 is positioned on a suctionside of the pump system 24 and can include at least one filtration pack122 including a plurality of filter elements 124. The filtration pack122 can include a frame 125 or other structure to which the filterelements 124 are attached. The frame can include a plurality of topstruts 126, a plurality of bottom struts 128, and a plurality of sidestruts 130 connecting the pluralities of top and bottom struts 126, 128.The frame 125 can be constructed of, for example, polyvinyl chloride(PVC), polypropylene, polyethylene, or any other suitable material(s).While a particular frame 125 is depicted, one skilled in the art wouldunderstand that different types of frames could be used to support aplurality of filter elements 124 and allow the filtration pack 122 to bereplaced, as will be discussed in greater detail below. For example,only one of the top struts 126, the bottom struts 128, and the sidestruts 130 can be utilized, two of the top struts 126, the bottom struts128, and the side struts 130 can be utilized, or any other configurationcan be utilized to hold and position the filtration packs 122. Inillustrative embodiments, the frame 125 provides spacing between thefiltration unit 120 and the bottom wall 102 of the separation vessel 26,which allows for accumulation of solids adjacent the bottom wall 102, aswill be discussed in greater detail below. In some embodiments, thefiltration unit 120 and/or the filtration packs 122 are self-supportingin that they can be set within the separation vessel 26 without beingattached to any portion of the separation vessel 26.

Each filtration pack 122 can include any suitable number of filterelements 124, for example, between about 10 and about 1000, betweenabout 100 and about 800, between about 200 and about 600, between about300 and 500, or about 450 filter elements 124. In an illustrativeembodiments, multiple filtration packs 122 each having 25 filterelements 124, can be utilized. In one such embodiment, 18 filtrationpacks 112 each having 25 filter elements 124 (with a total of 450 filterelements) can be utilized.

While the filter elements 124 are depicted as being vertical, the filterelements 124 can optionally be horizontal or one or more filtrationpacks 122 can include filter elements 124 that are vertical and one ormore filtration packs 122 can include filter elements 124 that arehorizontal. In illustrative embodiments, each of the filter elements 124in the filtration pack 122 can be parallel to one another. Additionally,while the filter elements 124 are shown as being nested in asquare-shape with parallel rows and columns of filter elements 124, asseen in the top elevational view of FIG. 14A, the filter elements 124can be nested in other configurations. For example, the filter elements124 of individual rows can be aligned, but the filter elements 124 inadjacent rows can be offset, as seen in FIG. 14B, the filter elements124 can be formed into a hex ring, as seen in FIG. 14C, or the filterelements 124 can be arranged in any other suitable configuration. Stillfurther, while the filtration packs 122 are shown as being arranged inparallel, the filtration packs 122 can be arranged in series and/or inparallel.

As best seen in FIG. 5, each filter element 124 can generally includefilter media 140, which can be for example, cylindrical surrounding acentral hollow core 142, a top, open end cap 144 partially enclosing atop end 146 of the filter media 140, and a bottom, closed end cap 148enclosing a bottom end 150 of the filter media 140. A filter elementoutlet tube 154 can extend through, for example, the top, open end cap144 to allow fluid to flow therethrough. The filter media 140 can benon-woven and can be made of, for example, glass blown fibers or anyother suitable material. In some embodiments, pore size for the mediacan be between about 1 and about 500 micrometers. The top, open end cap144 can be made of, for example, polyester or any other suitablematerial. In addition, the top, open end cap 144 can include acompression fitting for creating a fluid-tight seal with the filterelement outlet tube 154. The bottom, closed end cap 148 can be made of,for example, glass-filled nylon or any other suitable material.

Pre-separated fluid moves from an outside of the filter media 140,through the filter media 140, into the central hollow core 142, and outthe filter element outlet tube 154, as shown by arrows 155 a-155 c, asseen in FIG. 5. Each of the filter element outlet tubes 154 combine intoan outlet manifold 156 for movement out of the separation vessel 26.Each of the outlet manifolds 156 is in fluid communication with arespective third transfer line 47 to transfer fluid through the manifold88 to the source tank(s) 22. Each filtration pack 122 can include anysuitable number of outlet manifolds 156 in fluid communication with anysuitable number of filter elements 124.

In illustrative embodiments, the filtration unit 120 includes at leasttwo filtration packs 122. In illustrative embodiments, the filtrationunit 120 includes two filtration packs 122, each including 64 filterelements 124, as seen in FIG. 3. As described above, each of thefiltration packs 122 includes a frame 125, wherein adjacent frames 125can be removably attached to one another.

While the separation vessel 26 is shown as being generally rectangularin shape, one skilled in the art will understand that the separationvessel 26 can have any suitable shape, for example, square-shaped,cylindrical, or any other suitable geometric shape. In illustrativeembodiments, the separation vessel 26 can include sloped inner surfaces157 (FIG. 13A) to allow solids separated by the filter elements 124 tocollect in a central collection region 158. In other illustrativeembodiments, the bottom wall 102 can be sloped, as seen in FIG. 13B. Instill other illustrative embodiments, the separation vessel 26 can becylindrical in shape with an inverted cone bottom 159, as seen in FIG.13C. In illustrative embodiments, the separation vessel 26 can includeone or more drains 161 in the bottom wall 102, adjacent the bottom wall102, or in any other suitable location to remove collected solids fromthe separation vessel 26.

The filtration unit 120, including the filtration packs 122 and theindividual filter elements 124 of the filtration packs 122, incombination with the rate of flow through the separation vessel 26create a low flux through the filtration unit 120. More particularly, byincreasing the number of overall filter elements 124 (e.g., by includinga number of filtration packs 122 or a single filtration pack 122 withmultiple filter elements 124), a total square footage of filter media isincreased or maximized. In illustrative embodiments, the flux throughthe filter elements 124 can be less between about 0.001 gallons perminute per square foot (GPM/ft²) and about 0.05 GPM/ft². In otherillustrative embodiments, the flux through the filter elements 124 canbe less than or equal to about 0.01 GPM/ft². In still other illustrativeembodiments, the flux through the filter elements 124 can be less thanor equal to about 0.008 GPM/ft²). In yet other illustrative embodiments,the flux through the filter elements 124 can be less than or equal toabout 0.005 GPM/ft². In some embodiments, the flux through the filterelements 124 can be between about 0.001 GPM/ft² and about 0.01 GPM/ft²,or about 0.005 GPM/ft². To achieve the desired flux, the flow ofpre-separated fluid into the separation vessel 26 and processed fluidout of the separation vessel 26 can be the same. In some illustrativeembodiments, the flow of pre-separated fluid into the separation vessel26 and the flow of processed fluid out of the separation vessel 26 canbe between about 10 gallons per minute (GPM) and about 1000 GPM. Inother embodiments, both flows can be between about 10 GPM and about 600GPM or between about 50 GPM and about 400 GPM. In yet other illustrativeembodiments, the flow can be about 300 or about 350 GPM. The flow ratecan vary, so an overall surface area of the filter elements 124 can bevaried to achieve a flux within the ranges desired herein. In someillustrative embodiments, the flow of pre-separated fluid into theseparation vessel 26 and processed fluid out of the separation vessel 26can be different.

In some embodiments, the flow rate through the vessel 26 (and thus,through the filtration unit 120) is variable (per the ranges discussedabove). In such embodiments, the filter element surface area can bevaried in order to achieve the target flux rates discussed above. Inthis manner, the number of filtration packs 122 and/or the dimensions ofthe filter elements 124 within a filtration pack 122 can be varied toachieve the target flux rates for a particular flow rate. In thismanner, the filtration packs 122 are modular, as will be discussed ingreater detail below, in that each pack can be individually inserted andremoved from the vessel 26.

An increased square footage of filter media minimizes the flow rate permedia area (or flux). At very low flux rates per unit of media area, thedirt or particle holding capacity of the filtration unit 120, thefiltration packs 122, and the individual filter elements 124 increasesexponentially, which leads to longer operation time before thefiltration unit 120, the filtration pack(s) 122, and/or the individualfilter elements 124 need to be changed due to limited differentialpressure. The mechanism of ultra-low flux theory is that particles donot have a large enough face velocity to penetrate or clog pores in thefilter media 140 of the filter elements 124. More particularly, solidparticles hit the filter media 140 and fall to the bottom of theseparation vessel 26, rather than collecting in the filter media 140.Conversely, at a higher flux, the particles would have a large enoughface velocity to penetrate and clog the pores in the filter media 140 ofthe filter elements 124. The systems described herein capitalize on theultra-low flux theory by increasing the number of filter elements 124through which the pre-separated fluid flows, thereby decreasing the fluxto a low enough number that filter element 124 life (and, thus,filtration unit 120 and filtration pack 122 life) is lengthened fromseveral days to months. This increased life decreases operationalexpenditures dramatically, as will be discussed in more detail herein.

The particle separation system 20 can include a control system 168 forcontrolling operation of the system 20. In some embodiments, as seen inFIG. 6, the pump system 24 includes inlet and outlet pumps 170, 172,which can be controlled by variable frequency drives. In someembodiments, the control system 168 can include electronically actuatedball valves 174, 176 that control flow of pre-separated fluid throughthe first and second transfer lines 40, 44 into the separation vessel 26and through the third and fourth transfer lines 47, 50 out of theseparation vessel 26, respectively. In some embodiments, the controlsystem 168 can include one or more flow meters 178, 180, for example,within the first and/or second transfer lines 40, 44 and/or within thethird and/or fourth transfer lines 47, 50 for monitoring flow into andout of the separation vessel 26, respectively. In some embodiments, thecontrol system 168 can include a pressure sensor 182 within the firstand/or second transfer lines 40, 44 to monitor a pressure ofpre-separated fluid into the separation vessel 26. In some embodiments,the control system can include one or more level sensors 184 within theseparation vessel 26 for monitoring a level of fluid within theseparation vessel 26. One or more level sensors 186 can also be includedin the source tank(s) 22 for monitoring a level of fluid. The controlsystem 168 receives feedback from the various sensors within theparticle separation system 20 and changes parameters of the system basedon such feedback. The feedback can include, but is not limited to, inletflow rate, outlet flow rate, sensing of different conditions, alarms,notifications, or any other suitable feedback.

Referring now to FIG. 7, a further embodiment of a separation vessel 226is depicted. The separation vessel 226 can be included in any of thesystems disclosed herein, can include any of the features describedabove with respect to FIGS. 1-6, and can function in the same manner(i.e., at a high flow rate and/or low flux). The separation vessel 226includes a filtration unit 220 with a plurality of filtration packs 222including a plurality of filter elements 224. The filtration unit 220will now be described in detail, it being understood that all othercomponents and features of the separation vessel 226 (and the system inwhich the separation 226 vessel is employed) can be as disclosed withrespect to the vessel 26 of FIGS. 1-6 and the system in which the vessel26 is employed, for example, as seen in FIGS. 14A-14C.

The separation vessel 226 includes a plurality of walls 230 forming theseparation vessel 226 that form an internal or main filtration chamber232. The filtration packs 222 of the filtration unit 220 occupy at leasta portion of the internal chamber 232. Referring to FIG. 8, eachfiltration pack 222 can generally include a plurality of filter elements224 arranged in a parallel manner. In some embodiments, the filtrationunit 222 includes 25 filter elements 124, for example, in a five by fiveorientation. In other embodiments, any number of filter elements in anyorientation can be utilized.

First ends 234 of the filter elements 224 can be positioned in a frame236 and second ends 238 of the filter elements 224 can be connected to amanifold 240. The frame 236, which can be made of steel or anothersuitable material, can include a plurality of slots (not shown) forinsertion of a second end 238 of each filter element 224 in each of theslots to retain the filter elements 224 within the frame 236 and inrelation to one another. In other embodiments, the filter elements 224can be retained within the frame 236 in any suitable manner. Themanifold 240, as seen in FIGS. 8 and 9, is a hollow structure with aplurality of input ports 242 for connection of an outlet tube 244 ofeach filter element 224 and an outlet port 243, as will be discussed ingreater detail below. In some embodiments, each outlet tube 244 can fitwithin a corresponding port 242 of the manifold 240 through aninterference fit. In such an embodiment, an O-ring 150 can be positionedaround the outlet tube 244 to further the interference fit, create aseal, and prevent leakage between the outlet tube 244 and the port 242.The ports 242 and the outlet tubes 244 are positioned and aligned suchthat each of the filter elements 224 of the filtration pack 222 can beconnected to the manifold 240 at the same time. In other embodiments,the input ports 242 and the outlet tubes 244 can be formed in anysuitable manner that would provide for quick and easy attachment of aplurality of outlet tubes 244 of a plurality of filter elements 224 to aplurality of input ports 242 of a single manifold 240 at the same time.

As further seen in FIG. 9, the filtration pack 222 can include a numberof arms 260 connecting the frame 236 and the manifold 240 and includinglooped ends 262 that allow for connection of an apparatus for liftingthe filtration pack 222. In some embodiments, the arms 260 can be in theform of straps or another suitable flexible elements. In otherembodiments, the arms are made of a more rigid material. The arms 260hold the filter elements 224, the frame 236, and the manifold 240together. Further, each filtration pack 222 can be lifted by the loopedends 262 of the arms 260 to insert and remove the filtration packs 222from the separation vessel 226. In other embodiments, the arms 260 caninclude any other suitable structure for holding and moving thefiltration packs 222. As seen in FIG. 7, a plurality of filtration packs222 (that are the same or different) can be inserted into the separationvessel 226. While the filtration packs 222 are shown as occupying mostof the separation vessel 226, the filtration packs 222 may not occupythe entire separation vessel 226 (i.e., there can be open space withinthe vessel 226).

As best seen in FIG. 10, a bottom perspective view of the filtrationpack 222 is depicted. Each filtration pack 222 includes a molded end capstructure 263 that is separate from or an integral part of the frame236. The end cap structure 263 is molded in a square shape and caninclude a number of alignment structures 264 (e.g., circular slots,apertures, or other aligning structures) for holding ends of each of thefilter elements 224 in position. The alignment structures 264 canfurther include connecting structures 265 that couple the alignmentstructures 264 to individual square-shaped members 266 that togetherform the end cap structure 263. While one particular member of providingalignment features to ends of the filter elements 224 is depicted, anyother suitable alignment feature can be utilized. Further, the shape ofthe frame 236 and/or molded end cap structure 263 can be varied toaccommodate filtration packs 222 of different shapes and/or sizes.

Referring back to FIG. 7, the separation vessel 226 further includesprocessed fluid conduits 270 on opposing sides of the separation vessel226. The conduits 270 can be attached to an inner surface of a wall 230of the separation vessel 226 by brackets or any other suitable manner.The conduits 270 are configured to transport clean fluid (i.e., bypulling the fluid through the vessel 226 utilizing a downstream pump)from the filtration packs 222 out of the separation vessel 226. Moreparticularly, pack conduits 272 are connected between each of outletportion 243 and a respective processed fluid conduit 270.

When the filtration packs 222 are first inserted into the separationvessel 226, the filter elements 224 are clean and dry and, thus, createan upward buoyant force. In order to retain the filtration packs 222 inplace within the separation vessel 226 (in a vertical direction),retention straps 280 can be attached, for example by brackets or anyother suitable mechanism, to opposing walls 230 of the separation vessel226. In some embodiments, the retention straps 280 are positionedimmediately above the manifolds 240 when the frame 236 is positioned ona bottom wall of the separation vessel 26. In other embodiments, theretention straps 280 can be located at any suitable position. While theretention straps 280 are shown as being made of a flexible material, thestraps 280 may alternatively be made of a rigid material or acombination of flexible and rigid materials.

Still referring to FIG. 7, the manifold 240 of each of the filtrationpacks 222 is coupled to the conduits 270 by the pack conduits 272. Asdescribed in detail above, the contaminated is pulled through theseparation vessel 226 by a pump downstream of the separation vessel 226.In this manner, the systems disclosed herein are non-pressurized or lacka pressurized vessel (i.e., the system is at atmospheric pressure).Instead, the systems disclosed herein utilize a suction-side pump thatdraws fluid through the system. One advantage of a non-pressurizedsystem is cost. Pressurized systems require specific vessels that costsignificantly more for the same amount of filtration. Utilizing anon-pressurized system eliminates the need for such expensive vessels.

In some embodiments, as seen in FIGS. 11 and 12, any of the separationvessels herein can be included as part of a two (or more) stagefiltration system 300. For example, the separation vessels discussedherein are utilized to separate particles from a pre-separated fluidand/or to skim oil from an oil/water emulsion. It may also be desirousto provide a coalescing stage to remove oil and/or to provide otherfiltration steps. Some systems 300 can include any number of separationvessels 326 (which can be any of the separation vessels disclosedherein). Pre-separated fluid is provided from a tank or other site (seeFIG. 12) through a distribution manifold to a number of differentseparation vessels 326. The pre-separated fluid is pulled through eachof the separation vessels 326 by a respective pump 328 positioned, forexample, on a pump skid 330. The pumps 328 can then pump processed ortreated fluid from the separation vessels 326 to additional treatmentstages, for example, coalescers 340, which remove oil from the treatedfluid. A collection manifold 342 can be positioned between the pumps 328and the additional filtration stages 340 to control the flowtherebetween and to monitor the fluid (e.g., the quality, pressure,etc.) flowing therebetween. While coalescers are discussed, anyadditional filtration treatment process(es) can be utilized incombination with the separation vessels 326 and/or numerous additionalfiltration treatment processes can be utilized. In some embodiments,absorption beds can be utilized. In other embodiments, the otherfiltration or treatment processes can be pre-treatment processes in thatthey can be positioned upstream (i.e., before) the separation vessels326.

In any of the embodiments discloses herein, one or more aerators orbubblers can be disposed, for example, on the bottom wall 102, one ormore side walls 104, or at any other suitable location within theseparation vessel 26. The aerator or bubbler would act to inject air (orpossibly a fluid, such as water) into the separation vessel 26 to createa disturbance, which may assist in moving fluid through the separationvessel 26 and/or in the filtration process.

In any of the embodiments discloses herein, a back-pulsing operation maybe implemented within any of the systems. More particularly, the flowthrough the separation vessel may be reversed to remove solids from thefilter elements of one or more filtration packs, and then may bereturned to the original flow direction. The back-pulsing operation mayimprove the life of the individual filter elements.

As can be seen from the foregoing figures, the separation vessels 26,226 of the particle separation system can be portable and replaceable.More particularly, the separation vessel 26, 226 can be on wheels or canbe capable of being placed on a trailer or other structure for movingthe separation vessel 26, 226. The separation vessel 26, 226 can beconnected and unconnected from the source tank(s) 22 (or other location)and the pump system 24 and can be removed from the particle separationsystem 20 and a new separation vessel 26, 226 can replace the originalseparation vessel 26, 226. Use of the separation vessel 26, 226 causesbuildup and soiling of the filter elements 124, 224 within theseparation vessel 26, 226. In current systems, the system must bestopped and the filter elements must be cleaned, which takes a longtime, thereby resulting in significant downtime, which leads to highercosts. In the present particle separation system 20, the separationvessel 26, 226 can be disconnected from the source tank(s) 22 (or otherlocation) and the pump system 24, 224 and immediately replaced with anew separation vessel 26, 226, resulting in very little downtime. Theold separation vessel 26, 226 can then be transported to a facility forcleaning of the filter elements 124, 224 and other components within theseparation vessel 26, 226. The separation vessel 26, 226 is, therefore,also portable. More specifically, the vessel can be transferred to, forexample, a flatbed truck or another vehicle for transport thereof and/orcan include wheels or other mobilizer for moving the separation vessel26, 226 short distances.

In some embodiments, the separation vessel 26, 226 can be modular. Morespecifically, the separation vessel 26, 226 can be equipped to hold anysuitable number of outlet manifolds 156, 240 for accommodating a numberof slots X for up to X filtration packs 122, 222. The separation vessel26, 226 can also be equipped with appropriate shutoff valves or otherequipment to deactivate one or more of the outlet manifolds 156, 240. Inthis manner, dependent upon a particular application, any number of theslots X can include filtration packs 122, 222. For example, if theseparation vessel 26, 226 includes six slots to accommodate up to sixfiltration packs and the separation vessel 26, 226 is utilized for afirst application, filtration packs 122, 222 can be installed in each ofthe six slots and all six filtration packs 122, 222 may be active. Inanother application, filtration packs 122, 222 may be installed in eachof the 6 slots, but less than six of the filtration packs 122, 222 maybe active. In yet another application, filtration packs 122, 222 may beinstalled in less than all six slots (for example, three). In situationswhere filtration packs 122, 222 are installed and not utilized or notinstalled at all, the respective manifolds may be deactivated. Theabove-described modular system allows for customization of a system byinstalling a suitable number of filtration packs 122, 222 and by furtherallowing for selective activation and deactivation of filtration packs122, 222 dependent upon the particular application.

In some embodiments, the systems disclosed herein can be offered as arental model. In this manner, site personnel do not need to remove andreplace hundreds of filter elements at once. Rather, the entireseparation vessel may be removed from a particular site and replace witha new separation vessel. This model also greatly reduces downtime, as ittakes significant time to remove and replace hundreds of filtrationelements.

While the various embodiments of the particle separation system 20described herein have been described as a standalone system, theparticle separation system 20 may optionally be used in combination withany other filtration, separation, or any other suitable systems. Inillustrative embodiments, one or more particle separation systems 20 maybe utilized in combination with one or more of hydrocarbon recoverytechnology, liquid-liquid separation technology, solids removaltechnology, or any other technologies for processing, filtering, and/orcleaning fluids.

It will be appreciated by those skilled in the art that while theinvention has been described above in connection with particularembodiments and examples, the invention is not necessarily so limited,and that numerous other embodiments, examples, uses, modifications anddepartures from the embodiments, examples and uses are intended to beencompassed by the claims attached hereto. The entire disclosure of eachpatent and publication cited herein is incorporated by reference, as ifeach such patent or publication were individually incorporated byreference herein. Various features and advantages of the invention areset forth in the following claims.

The invention claimed is:
 1. A particle separation system, comprising: avessel having at least one side wall and a bottom wall forming aninternal chamber within the vessel; a filtration unit positioned withinthe vessel and comprising: a first filtration pack comprising a firstplurality of filter elements having a first plurality of outlets on afirst end of the first plurality of filter elements; a first singlemanifold having a first plurality of inlets, a number of the firstplurality of inlets being equal to a number of the first plurality ofoutlets, the first plurality of outlets and the first plurality ofinlets being capable of coupling such that a flow through each of thefirst plurality of filter elements enters the first single manifold; thefirst single manifold including a first outlet channel for flow from thefirst single manifold to a processed fluid conduit; a second filtrationpack comprising a second plurality of filter elements having a secondplurality of outlets on a first end of the second plurality of filterelements; a second single manifold having a second plurality of inlets,a number of the second plurality of inlets being equal to a number ofthe second plurality of outlets, the second plurality of outlets and thesecond plurality of inlets being capable of coupling such that a flowthrough each of the second plurality of filter elements enters thesecond single manifold; the second single manifold including a secondoutlet channel for flow from the second single manifold to the processedfluid conduit; a first frame for holding the first filtration pack, thefirst frame including a first end cap structure comprising a pluralityof first alignment structures, each of the first alignment structuresholding a second end of each of the first plurality of filter elements,and a plurality of first connecting structures that connect the firstalignment structures to the first frame; and a second frame for holdingthe second filtration pack, the second frame including a second end capstructure comprising a plurality of second alignment structures, each ofthe second alignment structures holding a second end of each of thesecond plurality of filter elements, and a plurality of secondconnecting structures that connect the second alignment structures tothe second frame; wherein the first plurality of outlets of the firstfiltration pack are positioned and aligned such that all of the firstplurality of outlets are capable of coupling to all of the firstplurality of inlets of the first single manifold at the same time, andthe second plurality of outlets of the second filtration pack arepositioned and aligned such that all of the second plurality of outletsare capable of coupling to all of the second plurality of inlets of thesecond single manifold at the same time.
 2. The particle separationsystem of claim 1, wherein each of the first and second filtration packsis independently removable and replaceable such that each of the firstplurality of filter elements are removed together and each of the secondplurality of filter elements are removed together.
 3. The particleseparation system of claim 2, wherein pre-separated fluid flows into thevessel at a rate of between about 10 and about 1000 gallons per minute(GPM) and a flux within the filtration unit is less than or equal toabout 0.05 gallons per minute per square foot (GPM/ft²).
 4. The particleseparation system of claim 1, further including: a first set of armsextending between the first frame and the first manifold, the first setof arms connecting the first frame and the first manifold and retainingthe first plurality of filter elements in position; and a second set ofarms extending between the second frame and the second manifold, thesecond set of arms connecting the second frame and the second manifoldand retaining the second plurality of filter elements in position. 5.The particle separation system of claim 1, wherein pre-separated fluidis moved through the vessel using a pump positioned downstream of thevessel.
 6. The particle separation system of claim 1, further includinga plurality of vessels and a plurality of pumps for moving pre-separatedfluid through the plurality of vessels.
 7. A particle separation system,comprising: a vessel having at least one side wall and a bottom wallforming an internal chamber within the vessel; a filtration unitpositioned within the vessel and comprising: a filtration packcomprising a plurality of filter elements having a plurality of outletson a first end of the plurality of filter elements; a single manifoldhaving a plurality of inlets, the plurality of outlets and the pluralityof inlets being capable of coupling such that a flow through each of theplurality of filter elements enters the single manifold; and a frame forholding the filtration pack, the frame including an end cap structurecomprising a plurality of alignment structures, each of the alignmentstructures corresponding to one of the plurality of filter elements andholding a second end of the corresponding filter element, and aplurality of connecting structures that connect the alignment structuresto the frame; wherein the plurality of outlets are positioned andaligned such that all of the plurality of outlets are capable ofcoupling to all of the plurality of inlets of the single manifold at thesame time.
 8. The particle separation system of claim 7, wherein the endcap structure further comprises a plurality of substantiallysquare-shaped members that define the relative position of each of theplurality of filter elements with respect to one another.
 9. Theparticle separation system of claim 7, wherein the alignment structurescomprise one or more of circular slots or apertures.
 10. The particleseparation system of claim 7, wherein the filtration unit furthercomprises at least one arm connecting the frame to the manifold.
 11. Theparticle separation system of claim 10, wherein the at least one armincludes a looped end for lifting the filtration unit.
 12. The particleseparation system of claim 10, wherein the at least one arm is providedin the form of a flexible strap.
 13. The particle separation system ofclaim 7, wherein each of the plurality of outlets is sized and shaped toprovide an interference fit with a corresponding one of the plurality ofinlets.
 14. The particle separation system of claim 13, wherein ano-ring is positioned around each of the plurality of outlets to seal theinterference fit.
 15. The particle separation system of claim 7, furthercomprising at least one pump and at least one transfer line fluidlycoupling the at least one pump to the vessel.
 16. The particleseparation system of claim 15, further comprising a control system thatreceives feedback from one or more of a pressure sensor in the at leastone transfer line, a flow meter in the at least one transfer line, or alevel sensor in the vessel.
 17. The particle separation system of claim16, wherein the control system changes parameters of the particleseparation system in response to the feedback.
 18. The particleseparation system of claim 16, wherein the control system controls atleast one electronically actuated valve positioned in the at least onetransfer line.
 19. A particle separation system, comprising: a vesselhaving at least one side wall and a bottom wall forming an internalchamber within the vessel; a filtration unit positioned within thevessel and comprising: a filtration pack comprising a plurality offilter elements having a plurality of outlets on a first end of theplurality of filter elements; a single manifold having a plurality ofinlets, the plurality of outlets and the plurality of inlets beingcapable of coupling such that a flow through each of the plurality offilter elements enters the single manifold; and a frame for holding thefiltration pack, the frame including an end cap structure comprising aplurality of alignment structures, each of the alignment structurescorresponding to one of the plurality of filter elements and holding asecond end of the corresponding filter element, and a plurality ofconnecting structures that connect the alignment structures to oneanother; wherein the plurality of outlets are positioned and alignedsuch that all of the plurality of outlets are capable of coupling to allof the plurality of inlets of the single manifold at the same time.